!

DRAFT

INDUSTRY CODE PERMANENT ANCHORS, LIFELINE AND

RAIL INSTALLATIONS

FOR WORKING AT HEIGHT

VERSION # 7c

Working at Height Association Limited PO Box 91, LANE COVE, N.S.W. 1595

ABN 79 116 837 819

PREFACE

The Standards Australia publication AS/NZS 5532 - Manufacturing requirements for single-point anchor devices used for harness-based work at height, prescribes the design and testing requirements for anchor points used for fall protection. In addition, AS/NZS1891.2 Industrial Fall Arrest Systems and Devices (Horizontal Lifeline and Rail Systems) provides guidelines on the safe design and manufacturing guidelines for horizontal systems and AS/NZS1891.3 Industrial Fall Arrest Systems and Devices provides guidelines on the safe design and manufacturing guidelines for vertical systems.

Up to this time, industry has used a system of self-certification to determine the safe installation of these systems. Manufacturers have also provided guidelines. However the definitions of safe installation and adequate documentation have never before been defined in a method consistent with industry expectations.

Market demands have also called for incremental documentation to provide industry with a set of principles of installation specific for these types of applications, rather than a sole reliance on the traditional, generic Codes of Practice published by the Federal, State and Territory Regulators.

This Industry Code document is intended to provide that further guidance. It is intended for use by installation companies, inspection entities, end users, facility managers and building owners on the recommended best practice methodologies to ensure safe access to a system, system design, installation and inspection of both horizontal and vertical static lines as well as permanently installed anchor points.

This document has been crafted with input from Regulators, Manufacturers, Industry Associations and people with technical knowledge in the subject. It is also the outcome of a period of significant public consultation and input and we therefore commend its use by all entities with an interest or need in managing these safety systems.

Table of Contents

SECTION 1 - DEFINITIONS 4 ........................................................................................

SECTION 2 – GENERAL 8 ...........................................................................................

SECTION 3 - PRODUCT CERTIFICATION AND STANDARDS COMPLIANCE 9 .........

SECTION 4 – SYSTEM INSTALLATION PROCESS AND KEY RESPONSIBILITIES 11 .

SECTION 5 – DESIGN 13 ............................................................................................

SECTION 6 - INSTALLATION 16 ................................................................................

SECTION 7 - COMMISSIONING / TESTING / CERTIFICATION 18 ..........................

SECTION 8 – DOCUMENTATION / HANDOVER 21 ...................................................

SECTION 9 – ONGOING INSPECTION AND TESTING 22 .........................................

SECTION 10 – WORKPLACE MANAGER RESPONSIBILITIES 23 ..............................

APPENDIX A – STANDARD REFERENCE DOCUMENTS 25 ........................................

APPENDIX B – TYPICAL ANCHOR APPLICATION TYPES 25 ....................................

APPENDIX C – EXTRACTS FROM AS/NZS 5532:2013 25 ........................................

APPENDIX D – ANCHORS FIXED TO ROOF SHEETING 25 .......................................

APPENDIX E – RESCUE CONSIDERATIONS 25 ..........................................................

APPENDIX F – LANYARD OR FALL PROTECTION DEVICE CONNECTION POINTS .........25

APPENDIX G – DESIGN & CONFIGURATION CONSIDERATIONS FOR HORIZONTAL LIFELINES & RAILS 25 ...............................................................................................

APPENDIX H – DESIGN & CONFIGURATION CONSIDERATIONS FOR VERTICAL LIFELINES & RAILS 25 ...............................................................................................

APPENDIX I – INSTALLATION TEAM COMPETENCE 25 ...........................................

APPENDIX J – CERTIFICATION / COMMISSIONING REQUIREMENTS 25 ...............

APPENDIX K – VERIFICATION TESTS FOR ANCHORS 25 ........................................

APPENDIX L – INSPECTION CHECKLIST 25 ..............................................................

APPENDIX L – INSPECTION CHECKLIST – GENERAL INSPECTION CRITERIA 50 ..

APPENDIX M – ANCHOR LAYOUT AND SPACING GUIDELINES 51 ..........................

APPENDIX N – HORIZONTAL SYSTEM LAYOUT AND SPACING GUIDELINES 57 ....

APPENDIX O – COMMON ISSUES RELATING TO POOR SYSTEM DESIGN 59 .........APPENDIX P - SUGGESTED CHECKLIST FOR A SYSTEM CERTIFIER 60 ................

APPENDIX Q - SUGGESTED CHECKLIST FOR A WORKPLACE MANAGER 61 ........

APPENDIX R - SUGGESTED CHECKLIST FOR ANCHOR SYSTEM INSPECTION – ONGOING RE-CERTIFICATION 62 .............................................................................

APPENDIX S - FREQUENTLY ASKED QUESTIONS AND ANSWERS 64 .....................

SECTION 1 - DEFINITIONS

1. Batch Number A permanent alpha/numerical marking on an item tracing the materials and item to the source materials at production.

2. Certifying Body An independent, third party organisation that has overseen and/or reviewed the testing of a product in accordance with a prescribed Standard and verified its performance against the entire testing regime of that Standard to confirm the product can be marked with a certification mark.

3. Certified Product A product that has been certified by an Certifying Body as passing all the prescribed manufacturing and performance (type) tests outlined in a given Standard and as such carries a mark of certification by the Certifying Body as being a verification of that process.

4. Competent Person A person who has, through a combination of training, education and experience, acquired knowledge and skills enabling that person to correctly perform a specified task.

5. Diversion Anchor A secondary anchor used to divert a lanyard assembly to reduce/remove the risk of a pendulum fall.

6. Engineer - Structural A person who is eligible for Corporate Membership of Engineers Australia or the Institute of Professional Engineers, New Zealand and who has appropriate experience and competence to assess the integrity of a building or structure for the purpose of supporting the loads imposed by anchorage points.

7. Fall Arrest System Personal fall protection system for work at a height by which a fall is intended to be arrested to prevent the collision of the user with the ground or structure.

8. Friction Anchor (fixing) An anchor fixing drilled into a concrete or masonry substrate and held in place via a drop-in expanding anchor that relies on friction to remain secure.

9. Glued-in Anchor (fixing) An anchor fixing drilled into a concrete or masonry substrate and held in place via an epoxy filler that sets before the anchor is commissioned.

10. Horizontal Lifeline or Horizontal Rail A linear anchor which allow users of fall arrest equipment the flexibility of lateral movement, without having to disconnect from the anchorage.

11. Installation Certification A product installation that has been certified as meeting the requirements of the Manufacturer’s installation instructions in order to be able to perform to the specified design and use requirements.

12. Installation Inspection The procedure by which a competent person (Installation Inspector) assesses the completed anchor installation as to its compliance with the Standard, relevant Code of Practice, manufacturers’ installations instructions and suitability for ongoing use by an end user such that their safety is assured.

13. Manufacturer An entity that manufactures products specifically designed for fall protection, designed to comply with Australian and New Zealand Standards.

14. Permanent Anchor An anchor point, for attachment of a fall arrest lanyard or lifeline, installed on a building or structure, intended to remain in place and be used at regular intervals by any qualified persons.

15. Portable Anchor An anchor that by virtue of its size and weight can be placed temporarily on a building structure and retain a load rating the equivalent of a fall arrest load without moving on the building surface (example – free standing weights).

16. Prescribed System Refers to a series of components provided from multiple sources and deemed suitable to be used together by the installation company for creating a permanent horizontal or vertical lifeline system. Prescribed systems are not required to be tested, but only be signed off by a Competent Person. Given the lack of testing accountability by virtue of their design, for this reason they are not recommended for use under this Industry Code.

17. Proprietary System A proprietary system in this Code refers to a set of components provided by a single manufacturer that are assembled together in order to create a permanent horizontal or vertical lifeline or rail system. A product certified to AS/NZS1891.2 is automatically recognised as a Proprietary System.

18. Qualified Installer A person who has been through defined training courses and passed the testing process sufficient to demonstrate their competency at installing a fall protection system to the Manufacturer’s defined requirements.

19. Re-certification Process A periodic review of an anchor point or lifeline system and the verification of its compliance with the original Installation Certification by a Competent Person.

20. Restraint Technique System Control on a person’s movement by use of a fall arrest anchor or lifeline with the use a fixed length lanyard or other adjustable component that physically prevent the user from reaching an area where a fall can occur.

21. Rope Access Techniques using ropes, normally incorporating two separately secured systems, one as a means of access and the other as back-up security, used with a harness in combination with other devices, for getting to and from the place of work and for work positioning.

22. Screw-in Anchor (concrete or masonry) (fixing) An anchor fixing drilled into a concrete or masonry substrate and held in place via coarse threads on the body of the anchor, which cut into the substrate to enable the anchor to grip. A screw-in anchor is deemed to be a friction anchor with regards to installation orientation and inspection / testing requirements.

23. Serial Number A unique permanent alpha/numerical marking on an item that identifies a system or item.

24. Shall ‘Shall’ indicates that a requirement is mandatory.

25. Should ‘Should’ indicates that a requirement is recommended.

26. Standard An Australian and New Zealand Standard that has been published by Standards Australia, following the prescribed drafting and public review process.

27. System Designer A Competent Person who has the responsibility to design an access system incorporating anchors or lifeline systems, or a combination of both, utilising the Industry Code, Codes of Practice, Standards and Manufacturer’s instructions such that the safety of the users of the system can be assured.

28. Temporary Anchor An anchor point, for attachment of a fall arrest lanyard or lifeline, installed or used on a building or structure that can be removed after use. (examples – tie-off adaptor, clamp)

29. Through-fix Anchor An anchor that is fixed through block-work, masonry or concrete and is secured on the reverse operating side by a locking nut.

30. Top fixed Anchor An anchor point, for attachment of a fall arrest lanyard or lifeline, used on a metal deck roof. It may be fixed to the roof sheeting or structure and may also be fixed through to the purlin, on the underside of the roof sheeting.

31. Undercut Anchor (fixing) An anchor fixing drilled into a concrete or masonry substrate and held in place via a drop-in expanding anchor that relies on friction, but that also has a feature that allows it to grip a ridge cut into the substrate. An undercut anchor is deemed to be a friction anchor with regards to installation orientation and inspection / testing requirements.

32. Vertical Lifeline or Vertical Rail Are vertical anchorages which allow users of fall arrest equipment the flexibility of vertical movement, without having to disconnect from the anchorage.

33. Workplace Manager A Person Conducting a Business or Undertaking (PCBU) or a person who is in charge of a site on which work activity is being completed.

SECTION 2 – GENERAL

1. SCOPE

This document relates to anchors, horizontal and vertical lifelines and rails that are permanently installed for use in general fall protection and rope access in workplaces, as well as the equipment used to gain access to those systems.

The document is also designed for use in conjunction with anchors complying with the manufacturing standard for anchors certified to AS/NZS5532 fall protection equipment certified to AS/ANZ1891 and the access/egress to the system complying with AS1657.

Installations of other products including horizontal lifelines and rails covered under Part 2 and vertical lifelines and rails covered by Part 3 that are manufactured in conformance with AS/NZS 1891 series, plus anchor requirements identified under AS/NZS 4488 - rope access, are also covered within this document.

A full list of reference documents is shown in Appendix A.

2. HIERARCHY OF CONTROL

The hierarchy of control for fall prevention shall be followed to determine the most appropriate control measure to reduce or eliminate the risk of a fall. Anchorage based fall protection systems are dependent on a high level of user skill, and are prone to misuse. Anchor based systems are less preferable to horizontal, vertical or passive systems (eg. Guardrail and platforms) and should only be considered when no suitable alternative solution can be identified. Refer to AS/NZS1891.4 and state or federal regulator Codes of Practice for more information.

3. OVERVIEW

For any working at heights situation where the use of harnesses is involved, there needs to be suitable lifeline systems and/or number of anchorage points provided to ensure safety for the users. This document seeks to provide guidance for installers of anchorage and lifeline installations where such systems of fall protection are often installed by a contractor, for use by an entirely different set of personnel.

In addition to the fall protection system itself, access to the location of system entry such that the workers can climb and egress from the system safely must be provided.

Each installation shall be designed, laid out, installed, commissioned, documented, inspected within a specified time frame and maintained to ensure its ongoing serviceability by those using the system for their own personal safety.

SECTION 3 - PRODUCT CERTIFICATION AND STANDARDS COMPLIANCE

1. UNDERSTANDING CERTIFICATION VS COMPLIANCE

There is quite a lot of misunderstanding about what product or system certification is vs. compliance. The differences are also complicated by the stage of product or system installation – from raw material specification, right through to installation. For example, a manufacturer may use steel or aluminium that has been manufactured to a certain manufacturing Standard, however the product that is produced at the end does not necessarily mean that it will comply with different product or installation Standard.

Outlined below is a summary of the key differences between product and system certification and compliance.

2. RAW MATERIAL COMPONENTS FOR A PRODUCT OR SYSTEM

Product compliance – A product is deemed to be ‘compliant’ with a Standard if a manufacturer can provide evidence by way of test results that it will at least meet the defined performance criteria of a specific Standard. This means the manufacturer is effectively self-certifying the performance of a product, in the absence of any additional third-party documentation.

Product certification – Is the process by which a testing laboratory verifies the ability of a product to pass a defined Standard. The laboratory must demonstrate they have the skills and equipment necessary to perform the testing function. A common method of assessing whether a laboratory is recognised as being able to perform this function is if they:

(1) Hold a current license for the National Association of Testing Authorities (NATA) accreditation;

(2) Have the testing regime that they are testing to on the scope of accreditation.

Some manufacturers of product are NATA accredited; therefore meaning they have the demonstrated skill and equipment to complete the required testing.

The initial product certification process is defined as ‘type’ testing. This verifies that the products supplied at the time of the test were deemed to be able to meet the conformance requirements of the Standard. Refer to Appendix E for more detail. It is also highly recommended that manufacturers undertake ‘batch’ or ‘product validation‘ testing. This testing involves repeated testing of batches of products using the same test methodology to prove the ongoing conformance of products sourced over time.

In-situ Testing – Another important component of a testing program is to verify a product or system has been tested incorporating its fixing substrate. Only then will it verify performance in an end-to-end environment. This is especially important with anchor point and systems installations as they are only a component of a total fall protection system. Each manufacturer should therefore be able to provide evidence that the product and substrate have been tested together and can sustain testing loads.

Certifying Body – A certifying body is an independent, third party organisation that provides a verification that a product has been tested to meet a defined Standard and that they have reviewed not only the test results but the test methodology to verify the conformance. Companies that are deemed suitable as certifying bodies are required to:

(1) Hold JAS/ANZ accreditation; (2) Have the specific Standard referenced in their approving schedule; (3) Provide competent auditors to verify the testing methodologies and results

for a specific product are true and accurate such that they can be marked with a conformance mark to be issued by that company.

(4) Provide certificates of conformance for a product to a specific Standard. There are a number of certifying bodies in Australia and New Zealand that are approved to act in this capacity. Each company has their own ‘conformance mark’ which effectively gives a person with a quick verification of the conformance of a specific product.

Certifying bodies require ongoing product validation testing to be completed in order for a company to maintain the product certification. This provides peace of mind to companies purchasing products on an ongoing basis that the products continue to perform as originally designed and tested, and that a change in sourcing vendor or product batches over time have not affected product performance.

A certified product is therefore always compliant, making it easy for a user to determine if a product will meet a Standard or not. A ‘compliant’ product may also be deemed as appropriate for selection/use and meeting a Standard, however the user needs to assess whether the documentation provided by the manufacturer is sufficient for them to make that choice. A ‘Compliant’ product is not necessarily inferior to a ‘Certified’ product; it just takes more work on behalf of the site owner of the system to make that assessment.

3. PRODUCT OR SYSTEM CERTIFICATION

The fact a raw material or components of a system have been certified or carry a conformance mark, does not mean that they are guaranteed to work unless they have been installed correctly. This is the difference between a product certification and a system or product installation certification.

Product or System Installation Certification – Is therefore the process by which a product or system installation is certified as being installed in accordance with manufacturer’s instructions and is certified to perform to the design requirements. The System Installation Certifier is accredited by the manufacturer to oversee the system installation and to ensure it is installed to their specifications.

A site owner can therefore verify a system has been installed correctly, if they have been issued with an installation certificate by a Qualified Installer. More information about this documentation is detailed in Section 7.

SECTION 4 – SYSTEM INSTALLATION PROCESS AND KEY RESPONSIBILITIES

The design, installation and commissioning of a fall protection system of anchors or lifelines involves a number of distinct steps, each performed by a person with defined skills. Some people may have the demonstrated skills and competency to perform more than one task.

MODIFY PER ATTACHED SHEET

1. INSTALLATION PROCESS

The installation process is a simple progression of steps to ensure a safe and reliable system is affixed to a defined structure. Regardless of the simplicity or complexity of the installation, it is essential all steps are completed to ensure a system is safe for use.

2. RESPONSIBILITIES

The core roles/functions of the various steps for each project as follows:

1. System Designer – is responsible for documenting the layout and positioning of the anchorages or lifeline, public protection and rescue considerations. They also define the system specification and gain manufacturer endorsement for their proposed layout/design. In some cases, this may be by way of a calculation program defining a system design load. In other cases, the system designer may access a product that offers design parameters from which a suitable design can be verified as able to perform to the design requirement (such as instruction manuals, technical literature).

2. Engineer – is responsible for assessment of the underlying substrate and its suitability to sustain structural loads.

3. Qualified Installer – installs the product in the correct location, following the manufacturer’s installation instructions, design layout and the engineer’s structural requirements.

4. Installation Certification – ensures that the engineer, system designer and manufacturer’s requirements are met for the particular installation when first installed.

5. Installation Inspector/Re-certifier – conducts routine inspections and maintenance of the system. This requires following the manufacturer’s certification documents and should be accompanied by qualifications following Standards such as ISO17025 testing requirements and ISO17020 requirements for in-service inspection. The inspector ensures that the system is suitable for ongoing use based on the manufacturer’s specifications.

Further details of these roles and their qualification requirements are more deeply defined in the Definitions and Appendix I.

The detailed series of tasks for the installation process to be completed are now discussed.

SECTION 5 – DESIGN

1. SYSTEM DESIGN, INCLUDING LAYOUT PLAN OR RIGGING LAYOUT

The safety of any fall protection safety system is primarily defined by the initial design. Poor design can increase the likelihood of a system being unused or impact the ability of a person to complete their task safely or effectively. Conversely, an excellent system design enables a person to access a system with ease, limiting the chance of an injury and indeed should assist them to complete a task efficiently without risk to themselves or others.

The initial stage of design is therefore the ‘Use definition’ by outlining the tasks to be completed at any time when a user is on the system (e.g. gutter cleaning, air- conditioning maintenance). The System Designer will then develop a layout that shall take into consideration access to the system and rescue in the event of a mishap. The System Designer should first consider a Restraint Technique System before a Fall Arrest system

2. MULTIPLE ANCHOR VS LIFELINE SOLUTION?

Utilising the Hierarchy of Control, it is generally safer to choose a passive system solution to provide a higher level of safety for users. If these are not practical, then the choice of a lifeline or multi-anchor solution might be deemed appropriate.

Horizontal lifelines and rail systems generally offer the user a safer environment than a multiple anchor point solution that requires the user to attach and detach to traverse an area in order to perform the required work. Multiple anchor point installations require a higher level of user skill to operate safely and also greater supervision. As such, multiple anchor points should not be considered before horizontal lifelines and horizontal rail systems in the Hierarchy of Control.

2. PRODUCT SELECTION

Once the primary applications and tasks are identified, product selection becomes an important feature in design. Appendix C demonstrates a multitude of typical anchor application types. Additionally, a horizontal or vertical system may be a more suitable alternative, or complementary alternative to anchors points given the building or structure design.

Whichever system is chosen, it is important for the system to be designed in accordance with a suitable product manufacturing Standard. A detailed summary of the product Standards is referred to in Appendix A, with additional information on Anchor point design and ratings shown in Appendix D.

Additional considerations in the layout are: • How many people are required to be working at one time; • The skill level of users; • Fall clearances; • Lanyard / Rope contact over sharp edges; • Pendulum falls • Supervision and objects on the structure that a falling person may come

into contact with.

There is a significant multitude of layout designs that might be considered for different structures, as well as products that are suitable for different applications. Appendices E, F, M and N detail major considerations in layout design principles and

hazards. Appendix O also highlights common issues associated with poor design.

3. STRUCTURAL ASSESSMENT

There is no point installing a fall protection system that is rated to defined performance loadings if the structure to which the system attached is fundamentally incapable. The System Designer must consider how the loads from the system or anchor are to be transferred to a structure in a fall event and ensure the structure is adequate.

Other considerations around structural assessment include product type, fixings, access to and from the system and the substrate.

System Designers shall ensure the system is fit for purpose, capable of sustaining loadings and that they can be used, installed, tested, inspected and maintained to the manufacturer’s requirements.

Different manufacturers offer different methods to assist a System Designer determine that loads are appropriate for a defined structure. Some manufacturers provide minimum design load guidelines. This information is usually supported by testing documentation.

Manufacturers of vertical and horizontal lifelines and rails also sometimes provide calculation programs that can provide a report detailing expected loads, using predefined engineering calculations. Whichever method is chosen, it is contingent upon the System Designer to ensure the load capacity of the structure is adequate and in the absence of definitive evidence, must call upon an Engineer to assess the structure accordingly.

4. ENGINEERING REVIEW AND DESIGN OF THE STRUCTURE

If an engineering review is required to be undertaken, the Engineer must perform calculations or assessments to determine if the potential loads being applied to a defined system will impact the structure negatively in any way.

In some cases, reference to an Engineer is essential wherever anchors are fixed into substrates whose structural ability cannot be readily verified. Some examples include:

• Natural Stone • Brickwork • Block-work • Hollow Core concrete • Slab with screeds • Edges of slabs

• Parapets • Timber • Roof sheets (Except where roof sheets and structure meets the

anchor manufacturers requirements defined in testing)

For concrete, (e.g. tilt-up panels, roofs), ensure that the concrete is at least 20MPa. This must be verified and proven. It is recommended that System Designer shall take account of these issues in design stage, well before installation takes place to ensure that the correct materials for installation are ordered and provided.

5. DESIGN - RESCUE

Whilst the chances of an incident can be very low, the overall layout, product selection and design of the installation is required to take account of the possible rescue requirements following a fall onto the system.

Whilst some anchor points are designed for two person loads, some products are not suited to perform a contact rescue from (where a second operator is lowered to retrieve a disabled operator) utilising the same anchorage point. In other cases, deforming anchors may become damaged in arresting a fall and may also not be suitable for rescue purposes.

In these circumstances, the System Designer may need to specify additional anchors to enable an effective rescue to take place. In finalising their designs, the System Designer shall therefore ensure that the documentation to be handed to the Workplace Manager lays out the intended (recommended) rescue method.

Refer to Appendix F for more details about rescue considerations during the design process. Additionally, Appendix G provides greater detail concerning anchor design for rope access applications.

SECTION 6 - INSTALLATION

1. INSTALLATION

The installation process is not one job – it involves the series of steps required to complete the end-to-end job of the installation. Components of the job include:

(1) Risk assess the work area for hazards; (2) Complete Safe Work Method Statements (SWMS); (3) Access the structure safely – utilising Elevated Working Platforms

(EWPs), ladders, scaffolding or other structure to complete the task; (4) Compile and transfer the system components and tools onto the worksite; (5) Install a safety system on a defined structure; (6) Obtain System Installation certification from the relevant person; (7) Following installation, remove the installation tools, excess materials and

debris from the structure; (8) Remove all temporary access equipment from the location; (9) Safely exit Qualified Installers and contractors from the site once complete.

2. WORKPLACE MANAGER

The Workplace Manager has a duty to ensure that the design, installation, testing (where required), certification, documentation and handover are carried out correctly. This includes ensuring that personnel are competent to carry out the physical works and that the correct process is followed in undertaking the design and installation.

Further, safety while the works are being carried out must be ensured at all times. This not only extends to the staff of the work place, but is for all contractors who are employed to complete and certify the installation.

In ensuring the safety of persons and the works, the competencies to operate equipment including any access equipment (e.g. EWP) must be maintained.

3. INSTALLER COMPETENCY

The installation team shall comprise individuals who demonstrate competency in the installation of anchorage points and/or lifeline systems, relevant to the works to be carried out. A team shall have installers that are fully trained in all aspects of the works to maintain their safety and the safety of others. They must also be able to demonstrate their rescue plan in the event of an emergency.

The team must also have individuals within it that have the skills to operate tools and testing equipment and shall be able to demonstrate they can safely complete the works (herein identified as Qualified Installers). The Workplace Manager has the responsibility to ensure that the installers performing the works required are capable of performing the work in a safe method.

Some examples of the verification of this competency could be as follows:

(1) Evidence of successful training completion of the Qualified Installer by the Manufacturer of the products being installed

(2) Work Safely at Heights training certificates, including rescue (3) White Card / Construction induction certificates (4) Building licenses (5) Other forms of relevant qualifications

The installation team shall understand all relevant aspects of the access equipment and anchors being installed and of any fixings, adhesives or compounds that may require special treatment to ensure they operate satisfactorily. Specialised product installation training shall be provided to the installers by the manufacturer. The manufacturer shall deem the installer competent in the installation of their product. Refer to Appendix H to view the minimum competencies for Qualified Installers.

4. INSURANCE

A core component of the verification process that is often missed is assessing the installer for their insurance coverage. A Qualified Installer will be able to produce a copy of their certificate of currency for Public Liability Insurance (typically for $20M or greater), Workers Compensation Insurance and Professional Indemnity Insurance to the Workplace Manager prior to any works being completed.

5. INSTALLATIONS INTO MASONRY / BLOCK-WORK / CONCRETE / HOLLOW-CORE PANELS

In these types of substrates, additional precautions are required to ensure the successful installation of a product. Proof load testing shall be performed on each and every anchor/fastener that is drilled in (i.e. friction or glued in). The load test shall be to 50% of the anchor’s design load (e.g. for 15kN anchors, test to 7.5kN). The load shall be held for a period of 3 minutes without failure.

If the concrete has visible signs of spalling, cracks wider than 1mm or chemical corrosion, then a sample should be taken and tested and verified that it is adequate. Copies of any testing documentation demonstrating the proof load completion should be supplied as a component of the hand-over documentation.

6. WORKING SAFELY AT HEIGHT

Every installer shall be suitably qualified and competent to work safely at heights, including the use of temporary systems for their own personal safety during the installation. These Qualified Installers shall provide a system for their own rescue, if there is a likelihood of them falling whilst installing the anchors or systems.

6.6 MANUFACTURER’S INSTRUCTIONS Every manufacturer should be able to supply instructions for the correct installation of their product. Installation of all anchorage and lifeline products shall be in accordance with the manufacturer’s instructions.

SECTION 7 - COMMISSIONING / TESTING / CERTIFICATION

In a sense, the commissioning, testing and installation certification process is a sub-set of the installation process. It is specifically called out in these guidelines however due to the importance of its place in the installation.

1. INSTALLATION CERTIFICATION

Installation Certification is different to Product Certification (covered in Section 3). The Installation Certification is the process by which a Competent Person certifies that a product installation is consistent with the manufacturer’s specifications and the layout specified by the System Designer.

A full certification shall consist of: ● Collating and reviewing the documentation for the system, including

anchor compliance statements, system design information, load calculations, proof loading results, testing records and user instructions.

● An inspection of the installed system that it meets the System Designer and Manufacturer requirements.

● Issuing a compliance certificate once all requirements are satisfied.

Self-issued certificates of compliance are only considered valid if they are provided in conjunction with the supporting evidence as outlined above. Some manufacturers may also have a centralised system of project or ‘system registration’ in place, which allows for an effective cross-reference that a design and installation is registered as being complaint. Verification of the availability of this process can be sought through the installer or directly with the manufacturer.

2. COMMISSIONING

Once the product has been installed, anchors shall be tested, if required.

All equipment installed shall be labelled with a weather proof data-plate. Each anchorage point or lifeline system shall be individually tagged. Each anchor shall be identifiable on a weatherproof layout located at the access points to the system.

Commissioning shall include the following documentation which is an essential part of the system manual:

1. A layout of anchors/rigging plan/lifeline design and types of devices used with each element clearly identified;

2. Inspection requirements and testing results (if required) for each anchor or lifeline system;

3. Labelling in accordance with appendix B (entry point plate) in AS/NZS1891.2; 4. Maintenance requirements and instructions.

Refer to Appendix J for further detailed information and documentation about the commissioning process.

3. ANCHOR MARKING/LABELLING

All anchor points shall be identified with a weather proof plate. Each anchor point shall be individually tagged, or identified on an anchor/rigging plan positioned at the entry point to the system.

Anchors shall be marked with a compliance plate that shows: 1. An indelible serial number or batch number. 2. The manufacturer and supplier’s name, trade mark or other means

of identification. 3. The manufacturer’s batch number or serial number of the component. 4. The product rating, in kN, or capacity (e.g. single person/limited free-fall). 5. The characters in the identification mark shall be readable and discernible

after installation. 6. Each anchor shall have an attached label or marking to identify it for

personnel attachment only.

The labelling shall be legible and durable taking account of likely weather conditions.

Following any incident such as a fall, affected anchors shall be tagged and withdrawn from service until an engineering assessment/inspection has been carried out and the anchor replaced, repaired or re-certified.

4. ON-SITE TESTING (also refer to Appendix K)

Two (2) different types of tests may be required, these being: 1/ Proof load test 2/ Verification test

Proof load test – The proof load test is used to prove that the connection to the substrate is adequate. This test shall be performed on anchors in masonry materials and may be prescribed by the designer for other types of anchors.

Proof loads are performed in axial tension (direct pull). On-going proof-loading (i.e. after initial installation) may require removal of the anchors for inspection for corrosion.

Products that shall be proof loaded include glued in anchors and friction type anchors.

● The proof load applied shall be 50% of the minimum anchor design load (e.g. apply 7.5kN to an anchor rated to 15kN and held for a period of 3 minutes without failure), unless the manufacturers requirements say otherwise.

● Pass / fail criteria – no visible permanent deflection/deformation or failure to hold the load.

● Proof load testing shall also be carried out for fasteners that attach components of a lifeline system to masonry materials.

● Proof load testing may also be required by the lifeline manufacturer of the termination components to the cable.

Verification test – No proof load test is required, a visual inspection is performed to confirm the installation is as per the manufacturer’s recommendations/specifications. The verification test includes the anchor or lifeline and the substrate. A typical example of a verification test would be a top fixed anchor attached to roof sheeting.

5. INSTALLATION CERTIFIER COMPETENCY

Certifier competency is a combination of training, education and experience covering:

1. Knowledge of relevant standards 2. Ability to assess the installed system and the substrate.

A certifier should have at least 3 years relevant experience of a combination of system design, installation and use of installed systems, unless a person can demonstrate equivalent relevant experience.

Some manufacturers may require that in order for a system to be initially certified or re- certified, they will only recognise that certification if the installer has been trained by the manufacturer as being capable of such an inspection. Verification of this can be by way of a certificate issued by the manufacturer to the Certified Installer / Re-Certifier detailing the validity of their training in that system type.

SECTION 8 – DOCUMENTATION / HANDOVER

Following installation the following documents shall be provided to the Workplace Manager:

1. SYSTEM CERTIFICATION

The compliance certificate shall include that: 1. The system and anchors are designed in accordance with the

standards referenced in appendix A, (and any other relevant design and material Standards), and

2. The system and anchors are installed in accordance with the System Designer’s specifications, Manufacturer’s instruction, Engineer’s requirements and in line with defined workplace health and safety conditions.

2. SYSTEM MANUAL

The system manual shall include at least the following information: ● Rigging plan/system layout –– instructions for the user on how the designer

intended the system to be used and accessed. This shall be site specific.● Product and manufacturer’s instructions for use● Any additional training requirements that may be required (specific to the

installation)● Supervision level required to use the as-designed installation● A listing of any special components required (lanyards, self-retracting

lifelines, mobile traveling devices, slings, rope protection etc.) to use the system safely

● The intended (designed) rescue method.● Test reports where applicable for proof loading. (see Section 7.4)● Requirements for any special protection needing to be placed or supplied by

the operatives, to protect the building, the equipment and the operators – this includes where edges are likely to be an issue to operator’s lanyards and any likely pendulum falls resulting from the layout of the anchor system.

● Any exclusion zonesThe system shall not be used until the worker has sited the system manual and certification (i.e. Verify the anchor or lifeline are within current inspection and/or testing date).

3. INSPECTION AND RE-CERTIFICATION REQUIREMENTS

The handover documentation should set out all relevant information with regards to on- going testing and inspection of the anchor or lifeline system. Note that inspection requirements differ between jurisdictions with some requiring 6 monthly inspections while others are 12 months. The documentation should be specific regarding inspection frequency, levels of inspection (including testing, where required), documentation and the like.

SECTION 9 – ONGOING INSPECTION AND TESTING

1. INSTALLATION INSPECTION

On-going inspections are called re-certifications and shall be carried out at the frequency and as prescribed in the handover documents. (See Section 8.2).

*Where state based legislation mandates a more frequent inspection regime than Australian/New Zealand Standards or the manufacturer’s requirements, then the higher order legislation shall take precedence, and that inspection frequency shall be applied.

2. ENGINEERED SYSTEMS INSTALLATIONS WITHOUT DOCUMENTS

If conforming documentation is not available, the system shall not be used until all aspects of certification are confirmed. On pre-existing installations, the process of verifying on-going suitability is the same as the process for new installations, irrespective of installation date.

3. INSPECTION / TESTING REQUIREMENTS

Inspect each anchor, horizontal and vertical lifeline system and record the details of the inspection. Checklists are mandatory. Checklists provided by manufacturers are preferred as they cover specific aspects of the manufacturer’s design. In the absence of specific checklists being available, sample ones are available in Appendices J, K and L. Marking the system and anchors with last inspection dates also enables the users to be able to determine if the system is safe for use based on last inspection date.

4. INSPECTION / TESTING COMPETENCY

Inspection and testing shall be carried out by competent person who is suitably qualified to undertake these works. Inspector competency is a combination of training, education and experience covering: 1. Knowledge of relevant standards (Eg.ISO17020, ISO17025, AS/NZS1891, AS1657) 2. Certification by the manufacturer that the inspector is trained to verify the

correct installation details of their product. 3. Ability to identify defects in the product and substrate. 4. Ability to identify deficiencies in the installation of the product and location. 5. The system and layout remains fit for purpose.

5. INSTALLATION INSPECTOR / RE-CERTIFIER

An Inspector or Re-certifier should have at least 3 years relevant experience of a combination of system design, installation and use of installed systems, unless a person can demonstrate equivalent relevant experience. There are programs for accreditation and training of inspectors and certifiers of equipment e.g. Course code MEN15004B, and 3rd party accreditation programmes that are evidence of competency of inspectors e.g. NATA accreditation for inspection to ISO17020 and on site testing to ISO17025, as well as manufacturer defined inspection programs.

SECTION 10 – WORKPLACE MANAGER RESPONSIBILITIES

The person who is in control of the workplace is referred to in this document as the Workplace Manager. The Workplace Manager may include the building manager, body corporate, the commercial tenant, the facility manager, the property owner, the employer etc.

1. AFTER THE INSTALLATION

After commissioning of the works, the system is handed over to the Workplace Manager.

2. WORKPLACE MANAGER GUIDELINES

Once the anchor or lifeline installation has been handed over, the Workplace Manager has the responsibility to ensure that:

- Handover documents are retained and updated as required - Procedures are developed to ensure that only persons trained in use of

the installation are allowed to use the system - User information is provided to system users. - A reasonable amount of supervision is provided to ensure that the systems

are used correctly. - That there are adequate rescue plans in place, which are practiced. - The system is used correctly, by suitably trained personnel - The system is maintained and inspected in a timely fashion in accordance

with the instructions set out in the Inspection and Recertification guidelines (refer to Section 9).

In addition to the Workplace Manager, other persons may also have concurrent responsibilities in regard to the proper use and maintenance of the anchor or lifeline installation (e.g. Subcontract Company who intends to use the installation).

3. INSPECTION AND RE-CERTIFICATION

This involves the process of conducting routine compliance inspections for all installations in the control of the Workplace Manager. They should seek to:

● Ensure that inspections are performed in a timely fashion. ● That the manufacturer’s recommendation/specification are adhered too ● Prior to and during use of the system, the user should conduct

ongoing inspections to ensure that any damage is identified and reported to the Workplace Manager.

● The system should not be allowed to be used if it is not current in regard to inspection and is not bearing markings indicating currency

● Each state has its own requirements for the frequency of anchor and lifeline inspection. These requirements are prescribed in state based OH&S Regulations, Codes of Practice or industry specific guidance material.

● Acts, Regulations and Codes of practise are higher order legislation than Australian Standards, and as such, when those documents prescribe how often anchors and lifelines are inspected, takes priority and precedence over the requirements Australian Standards or this document.

4. VERIFICATION OF ANCHOR DESIGN AND INSTALLATION

The Workplace Manager should ensure that they have documented evidence of the adequacy of the anchors i.e. that the anchor complies with the strength requirements of AS/NZS 1891.4 and the requirements of AS/NZS 5532. This is particularly important for anchors installed prior to October 2013 (the release date of AS/NZS5532). Where this is not available, they should take the anchors out of service. The anchors may be returned to service if such documentation is located or adequacy confirmed by engineering review.

Any review shall also include the adequacy of the substrate’s capacity. For any anchors installed after the release of AS/NZS 5532, these shall comply with this Standard.

Where a system is found to be deficient: ● Tag the anchor system out of use ● Upgrade the system to meet minimum requirements, or ● Remove the system and replace with one meeting the current requirements

5. UNCERTIFIED / NON-VERIFIED SYSTEMS

There may be an occasion when a Workplace Manager becomes aware of an anchor or lifeline installation on a new premises that they are unsure about. Even if it does have a compliance plate and is within service, what is the best process for assessing whether the product is suitable for use?

(1) Until further notice, check the system out of service until an inspection can be performed;

(2) Contact the last inspection company to review their documentation and provide copies of the latest data;

(3) If non-contactable, contact the installation company to determine the details of the system installation if available;

(4) If non-contactable, contact the manufacturer to determine the details of the system installation if available. They can arrange for a suitably qualified installer to visit the site and conduct an inspection;

(5) Only return the system to service when you have satisfied yourself the system is fit for use.

APPENDICES

APPENDIX A – STANDARD REFERENCE DOCUMENTS

APPENDIX B – TYPICAL ANCHOR APPLICATION TYPES

APPENDIX C – EXTRACTS FROM AS/NZS 5532:2013

APPENDIX D – ANCHORS FIXED TO ROOF SHEETING

APPENDIX E – RESCUE CONSIDERATIONS

APPENDIX F – LANYARD OR FALL PROTECTION DEVICE CONNECTION POINTS

APPENDIX G – DESIGN & CONFIGURATION CONSIDERATIONS FOR HORIZONTAL LIFELINES & RAILS

APPENDIX H – DESIGN & CONFIGURATION CONSIDERATIONS FOR VERTICAL LIFELINES & RAILS

APPENDIX I – INSTALLATION TEAM COMPETENCE

APPENDIX J – CERTIFICATION / COMMISSIONING REQUIREMENTS

APPENDIX K – VERIFICATION TESTS FOR ANCHORS

APPENDIX L – INSPECTION CHECKLIST

APPENDIX M – ANCHOR LAYOUT AND SPACING GUIDELINES

APPENDIX N– HORIZONTAL SYSTEM LAYOUT AND SPACING GUIDELINES

APPENDIX O – COMMON ISSUES RELATING TO POOR SYSTEM DESIGN

APPENDIX P - SUGGESTED CHECKLIST FOR A SYSTEM CERTIFIER

APPENDIX Q - SUGGESTED CHECKLIST FOR A WORKPLACE MANAGER

APPENDIX R - SUGGESTED CHECKLIST FOR ANCHOR SYSTEM INSPECTION – ONGOING RE-CERTIFICATION

APPENDIX S - FREQUENTLY ASKED QUESTIONS AND ANSWERS

APPENDIX A – STANDARD REFERENCE DOCUMENTS

Standard/Document How it relates

AS/NZS 1891.1 This is the manufacturing standard for harness and lanyards. There are no specific requirements in this standard relating to anchor systems.

AS/NZS 1891.2 This standard covers horizontal lifelines and life rails. Note the standard is in 3 parts – Proprietary systems - covers engineered systems as designed by suppliers of complete systems. The second part (Prescribed Systems) is a design developed by the drafting committee after extensive testing – it offers “off the shelf” designs of HLL’s providing they are installed strictly in compliance with the design. Beam and trolley systems are covered in the third section.

AS/NZS 1891.3 This standard covers vertical rope systems (both metal and fibre) and track systems. It also covers inertia reel style devices. There are specific load requirements for anchorages set out in the standard. The anchors generally used in AS/NZS 1891.3 are covered under AS/NZS 5532 with the exception of fixed ladders.

AS/NZS 1891.4 This is an advice document on how to select, maintain and use harness based working at height equipment. While it sets out some criteria applicable to anchors it is not possible to verify a system as complying with this standard. To comply with an AS/NZS standard in relation to anchors, compliance may only be claimed against AS/NZS 1891.2, AS/NZS 1891.3 or AS/NZS 5532

AS/NZS5532 This document covers single point anchors (for connection of one or two persons) including davits, tripods, beam style anchors and counterweighted systems. The standard is a manufacturing only standard and as such must be used in conjunction with this COP to comprise an entire installation.

AS/NZS 4488, parts 1 & 2

These documents cover rope access and part 2, which detail, the selection and safe use of equipment, sets out some parameters for anchor design. AS/NZS 5532 now provides more extensive information.

AS1657 The standard for the design, manufacture, installation of fixed ladders, platforms, walkways, guard-railing, stairways, used for equipment to gain safe access and egress to and from anchor systems.

IS017020 Standard on inspection bodies and what needs to be dealt with in an inspection of equipment. This is the standard to which NATA (National Association of Testing Authorities) accredits inspectors and certifiers of equipment.

IS017025 Testing standard for inspection companies to work to covering type testing, in situ testing and load testing of anchors. This is the standard to which NATA (National Association of Testing Authorities) organizations that test equipment.

APPENDIX B – TYPICAL ANCHOR APPLICATION TYPES

APPENDIX C – EXTRACTS FROM AS/NZS5532

AS/NZS 5532 calls for the following minimum ratings of anchor points – note they may be rated for one person or two:

Single point anchor devices may be either rated for limited free-fall arrest or fall arrest.

Limited free-fall arrest anchors for single persons shall be rated at 12 kN Free-fall arrest rated anchors for single persons shall be rated at 15 kN See Clause 5.2.

Anchors for two persons shall be rated in the following manner: (a) Limited free-fall arrest two person anchor: 18 kN (12 kN + 6 kN = 18 kN). (b) Free-fall arrest two person anchor: 21 kN (15 kN + 6 kN = 21 kN).

As far as practicable, all single point anchorages should be rated for fall arrest even though this Clause specifies a lesser strength for some categories.

The anchor device shall be designed to withstand a force equal to the rated capacity in all directions in which a force could be applied during a fall arrest. See Figure 8 for potential loading directions.

Rope Access anchors are to be rated at a minimum of 12 kN ultimate (limited free-fall), however the anchors should be rated at 15kN whenever possible so they are suitable also for use in fall arrest. Where both the working rope and the backup rope is intended to be connected to the same anchor, it is also preferable that the anchor be rated at 15 kN ultimate.

Maximum allowed angle 20 degrees from the horizontal – no axial tension (direct pull-out) allowed – Note these drilled-in anchors require regular testing also, and as such, become a potentially expensive option. (If the anchor is to be used in tension, it shall only be through bolted – i.e. NOT friction or glued in.)

Typical eyebolt in drilled in (friction/glued in/screw in) installation

APPENDIX D – ANCHORS FIXED TO ROOF SHEETING

ANCHORS FIXED TO ROOF SHEETING ONLY

AS/NZS 5532 provides testing for this application. The test is a type test only – it is used to prove the ability for the anchor to stay connected to a typical piece of roof sheeting under “laboratory” conditions.

When the manufacturer has undertaken type testing in accordance with AS/NZS 5532, then the conditions of the testing (e.g. roof sheeting type and thickness, fixing method, purlin type and spacing) forms the base requirement for site installation. The System Designer shall ensure that the following requirements are documented and met based on the type testing:

● Roof sheeting - same configuration ● Roof sheeting - same thickness (BMT) or thicker ● Purlin size - same size and thickness or deeper and thicker ● Purlin spacing - same or closer ● Fixings on the roof - in good condition ● Roof sheeting - in good condition

If these conditions are not met, then the anchor shall not be installed.

TYPICAL “TOP FIXED ANCHOR” (fixed to roof sheeting only with no connection to purlins) Illustration from AS/NZS 5532

Note that there are anchors in the market that fix through to the purlins as well.

APPENDIX E - RESCUE CONSIDERATIONS

Whilst anchors may sustain the impact loads created during a fall (dynamic loads), they may be incapable of handling the static and additional dynamic loads necessary to rescue a person – particularly if the nominated rescue involves the weight of a second person.

A rescue plan shall not include use of an anchor previously loaded in the fall unless the anchor AND the designed installation method takes account of rescue loads – this information should be verified and documented by the anchor System Designer. This information will likely require confirmation from the anchor manufacturer and also from the Engineer (structural) responsible for assessing the loads applied to the structure in a fall event if applicable.

Rescue plans shall be developed before work commences, and are an essential part of the Safe Work Method Statement (SWMS). Rescue plans will often require the provision of specific equipment to be used in the rescue.

Rescue plans will also generally require specific training for the users to ensure they understand how to use any equipment to swiftly perform a rescue.

Dialling 000 is NOT seen as an effective rescue plan. Response times by emergency services and the need for specialised skills and equipment mean that an on-site capability is required in most cases.

APPENDIX F – LANYARD OR FALL PROTECTION DEVICE CONNECTION POINTS

While AS/NZS 5532 is a Standard written about “single point” anchors, it does allow 2 persons to connect to a single anchor where the anchor (and the installation) is designed for this purpose. (Such anchors are designed for higher loads).

It is recommended that in all such cases there are 2 unique connection points on the anchor to clarify it is suitable for dual connection and there should not be a reliance on labelling to communicate this information given the risk it may fade, be removed or destroyed during use.

ROPE ACCESS ANCHOR CONNECTION POINTS – 1 POINT or 2?* The following advice applies specifically to rope access operators who have 2 ropes to connect, however it should be seen as good advice also for any situation where a single anchor is rated for use by 2 persons (i.e. 21 kN ultimate)

Rope access operators are required to connect independently at all times.

However in the case of an anchorage, the load combines when the load transfers back to the structure.

1. In line with trying to ensure that all permanent anchors are suitable for ease of use by Level 1 operators, it is recommended that there should be 2 separate connection points – one for each rope – even if there is only a single anchor.

2. The overall anchor design load should be a minimum of 15 kN ultimate as a minimum.

3. The anchor needs to be designed and installed with a strategy for any potential rescue in place.

4. The markings and user instructions need to clearly define the capacity of the anchor (necessary to ensure no connection of a second person unless rated as such).

5. The anchor needs to take into account likely directions of side loading from operator’s ropes and hardware.

Anchor installed for Rope Access use where hole pairs are orientated in North, South, East and West configurations – note this installation is mounted on a through roof bollard and is yet to be labelled. Only one user should attach to each anchor.

Another anchor set up for Rope Access use with pairs of holes in each orientation allowing 360 degree use. Note this unit is “top fixed” but is fixed through to purlins and uses roof sheeting only for plan bracing. Only one user should attach to each anchor.

ADVICE FOR DESIGNERS OF ROPE ACCESS ANCHOR POINT INSTALLATIONS

CONNECTION POINTS ● Keep work rope and backup rope connection points close together unless there is

a reason for them to need to be apart ● Keep connection points without sharp edges, by using rounded material,

chamfered holes etc. ● Set up connection points for use by karabiner or shackle – preferably do not rely

on operator tying into to anchor point ● Ensure connection point will not be loaded in a way that weakens it – sometimes

this may require a moveable head or design modification to achieve

LAYOUT ● Provide more anchors and less or no diversions to keep layout simple and less

chance of operator error ● Design systems to be as simple and straightforward as possible and wherever

possible, suitable for Level 1 operators – less chance of mistake and generally more economical in the long run

● Keep rope runs away from rotating parts, areas that are difficult to rig or feed ropes through, and away from sharp edges

● On building edges, consider installation of edge detail that will not damage rope and/or supply portable devices for rope protection (ensure they cannot drop!)

● Where glass balustrades are used, ensure rope is kept away from glass – often achieved by use of davit or steel framing with specific rope path

● Can all members of the team reach all required anchors safely? – Glass is not load bearing

● Has long-term maintenance of the anchor system been adequately considered? ● Will the system allow access to ALL the points likely to be required by the client

for maintenance purpose? This may include areas of roof, parts of façade, other structural elements on areas such as chimneys, cooling towers, cranes, gutters, façade and maintenance

● Does the system also need to allow for powered access for heavy-duty works? (I.e. Re glazing, painting etc.) Anchors are often installed capable of being used for both purposes.

RE-ANCHORS (RE-BELAY) ● Avoid these where possible, particularly on retrofits as it may be difficult to

prevent anchors needing to be drilled in and used in axial tension

● Use monorails in preference to individual anchors – monorails should be regularly fixed to substrate so that a failure of an individual fixing point will not render entire rail unsafe.

● Monorails should be designed to allow multiple operators and/or rescue capability

PUBLIC PROTECTION ● The layout of the system needs to consider how public protection will be

achieved. The planned manner needs to be communicated to the users clearly. ● Permanent elements may need to be supplied or installed to assist with public

protection (e.g. bollards, boarding and catch nets).

MANUAL HANDLING ● A rope access site is a work place – the designer must ensure that any hardware

intended for use on site by the crew can be safely handled and placed without undue strain and danger. This is likely to affect davits, counterweights, “needles” and the like. Consider how these are handled

● Heavy or bulky items are often built in broken down form to allow safe and simple carriage and placement.

RESCUE ● Ensure that rescue is considered at design layout stage and document ● Consider whether an emergency response team can access the area where an

injured worker is lowered to (e.g. A private balcony or inaccessible awning)

APPENDIX G – DESIGN & CONFIGURATION CONSIDERATIONS FOR HORIZONTAL LIFELINES & RAILS

Proprietary Systems – Horizontal Cable Horizontal cable systems for which the fall arrest performance of any selected layout design can be determined by a method or program which has been verified by means of performance testing of prototypes over an adequately representative range of layout configurations.

These systems are also known as ‘engineered’ systems. They comprise flexible lines with end anchorages and dependent on the system length intermediate brackets with mobile attachment devices that are capable of passing across the intermediate brackets without disconnection from the line and to which personal fall arrest equipment is connected. The system components and recommended installation configurations should be traceable to prototype or sample testing to AS/NZS 1891.2.

The systems are designed as a completed installation and must be installed by an accredited and competent installer who has been trained by the manufacturer of the system.

Proprietary Systems - Horizontal Rail Horizontal rail systems generally comprise a steel or other metallic structural member along which one or more mobile attachment devices run, each providing a travelling anchorage for connection of personal fall arrest equipment. The strength of the rail and its fixing to the supporting structure is determined by structural design calculation and testing.

Prescribed Configuration Systems Although the use of a Prescribed Configuration Systems as detailed in AS/NZS1891.2 Supp1:2001 is deemed to be legitimate, this Industry Code does not recognise the Prescribed Systems as being a suitable or preferred option for consideration. Extensive industry experience has shown that installers/sellers of these systems DO NOT take the required precautions to ensure the combination of components and their source are sufficient to provide the necessary safeguards. They therefore may do not provide the level of user safety and conformance with the Standards that Proprietary Systems offer.

In addition, the following elements are not automatically required or limited in a Prescribed system:

1. Use of intermediate brackets that allow mobile attachment devices to pass across the intermediate removing the need to attach, detach and attach.

2. Restriction of the overall length of the horizontal lifeline. 3. Restriction of the span length of the horizontal lifeline. 4. Restriction of the number of users of the horizontal lifeline. 5. Restriction of cable diameter, construction and material, stainless steel is

not permitted. 6. Line (system) energy absorbers are not permitted. 7. System height cannot be less than 1.5 metres above the user’s walkway.

System Design Requirements

The following requirements shall be incorporated into the design of horizontal lifelines and horizontal rail systems including associated documentation where appropriate:

1. The system shall not allow the fall arrest loading exerted on a user’s harness to exceed 6kN when the user is equipped with and is correctly using personal fall arrest equipment as specified in AS/NZS 1891.4.

2. Calculation software that provides the end anchorage forces and line deflections when arresting a fall shall be based either directly on test results or on interpolation of test results in respect of span lengths, and interpolation or extrapolation in respect of overall line length.

3. The components including terminations, cable and end anchorages are capable of supporting without failure a minimum force equal to or greater than twice the maximum fall arrest fall in the system.

4. End anchors are also required to be capable of supporting a force of 12kN at right angles to the axis of the cable in the direction of fall arrest.

5. For horizontal lifelines the minimum cable diameter shall be 8mm and shall be made of stainless steel or specialty low-stretch synthetic cable.

6. Swaged terminations shall be made from the same material as the cable to avoid an adverse reaction with the material of the wire cable e.g. dissimilar metal corrosion or cracking.

7. Intermediate brackets shall allow the horizontal lifeline to run freely through the aperture and to prevent damage to the cable.

8. Intermediate brackets are to be capable of supporting a force of 12kN at right angles to the axis of the horizontal lifeline and in the direction of the fall and its arrest.

9. Mobile attachment devices shall either be impossible to remove from the horizontal lifeline or horizontal rail systems or shall be removable by at least two consecutive deliberate manual actions.

10. Mobile attachment devices shall be capable of supporting a force or 15kN in the direction of intended loading without breaking and without deforming in a manner which permits inadvertent detachment from the horizontal lifeline or horizontal rail system.

11. Calculation of safe clearances below the system at any point shall be based on the maximum deflection of the system at that point when arresting a fall, including the effects of personal and line energy absorber extension, the maximum height of a user, harness D-ring stretch plus a further clearance of at least 1.0 m as specified in AS/NZS 1891.4.

12. The system must be installed as per the recommendations and documented installation instructions provided by the system manufacturer.

13. The system must be installed by a company trained and approved by the system manufacturer.

14. The use of components from multiple manufacturers in a system is not acceptable due to possible incompatibility and the likely event that they have not been tested together to demonstrate a known performance.

15. All system components shall meet or exceed the relevant requirements of AS/NZS1891.2.

System Configuration

Horizontal lifeline and horizontal rail systems can be designed / installed in either of two configurations which are outlined below:

1. Restraint Technique - A restraint technique system controls a person’s movement by physically preventing the person reaching a position at which there is a risk of a fall.

It consists of a harness that is connected by fall arrest equipment to a horizontal lifeline or horizontal rail system. The system must be installed and the correct use of the fall arrest equipment to prevent the user from reaching an area where a fall could occur or an unprotected edge.

A restraint technique system is suitable for use where: a) The user can maintain secure footing without loading the restraint line

and without the aid of any other hand hold or lateral support. When deciding whether secure footing can be maintained, consider:

i. The slope of the surface. ii. The supporting material type. iii. The surface texture of the surface and whether it is likely to be

wet, oily or otherwise slippery. b) The horizontal life lines are fitted with an inline shock absorber(s)

when required. c) The restraint technique system conforms with AS/NZS 1891 Industrial

fall- arrest systems and devices series.

Restraint techniques should only be used if it is not reasonably practicable to prevent falls by providing a physical barrier (for example, a guard rail). This is because restraint techniques require a high level of user skill to operate safely and also greater supervision. A restraint technique system must be installed by a competent person in accordance with the manufacturer’s instructions.

A restraint technique system components and end anchorages must be designed as a fall arrest system with regards to system design forces, in accordance with the principles outlined in AS/NZS1891.4. The principle of this is if a restraint technique system is exposed unexpectedly to fall arrest circumstances, then the system design will still prevent a catastrophic failure.

A fall arrest system must be used instead of a restraint technique system if any of the following situations apply:

a) The user can reach a position where a fall is possible. b) The user has a restraint line that can be adjusted in length so that a

free fall position cannot be reached.

c) There is a danger the user may fall through the surface, for example fragile roofing material.

d) The slope of the roof or work area is greater than 15 degrees.

2. Fall Arrest - A fall arrest system is intended to safely stop a worker falling an uncontrolled distance and reduce the impact of the fall. This system must only be used if it is not reasonably practicable to use higher level controls or if higher level controls might not be fully effective in preventing a fall on their own.

All equipment used for fall arrest must be designed, manufactured, selected and used in compliance with the AS/NZS1891 series of standards.

Key safety considerations in using fall arrest systems are: a) The correct selection, installation and use of the equipment. b) That the equipment and anchorages are designed, manufactured and installed

to be capable of withstanding a minimum of twice the maximum force applied to them as a result of a person falling. This equates to a factor of safety of 2:1.

c) That the system is designed and installed so that the person travels the shortest possible distance before having the fall stopped.

d) That there is sufficient available fall clearance. e) That worker’s using a fall arrest system wear adequate head and other

suitable personal protective equipment to protect them in the event of a fall.

f) That if the equipment has been used to arrest a fall it is not used again until it has been inspected and certified by a competent person as safe to use.

g) In the event of a fall a rescue procedure can be implemented.

Horizontal lifeline systems, whether designed for restraint technique or fall arrest, cannot be subjected to any user loading in normal service, other than substantially horizontal restraint technique forces. They cannot be used for work positioning purposes such as rope access use.

Horizontal rail systems can be designed for restraint technique, fall arrest and work positioning and subjected to user loading if approved by the system manufacturer.

System Installation Criteria

The System Designer and System Installer of the horizontal lifeline and horizontal rail systems must consider the following prior to and during the installation.

1. The structural capacity of the material that the horizontal lifeline and horizontal rail systems will attach.

2. The structure must be capable of supporting the design loads nominated by the system manufacturer for the specific installation as determined by the calculation software.

3. There is sufficient fall clearance. 4. The frequency of system use and number of users. 5. The operational environment, considering the effects on both

performance and maintenance requirements. 6. The slope of the roof that the system will attach to and the user

will walk on will determine the type of system: i. All systems must be designed for fall arrest forces

regardless of the system type.

ii. Consideration should be given to installing horizontal rail systems where the slope of the roof is greater than 10 degrees to eliminate system loading by the user which may cause system energy absorbers to deploy and intermediate brackets to deform as this will alter and reduce the system’s fall arrest performance characteristics.

iii. A roof with a slope of 15 degrees or greater is not suitable for the installation of a horizontal lifeline.

iv. A roof with a slope of 15 degrees or greater must have a horizontal rail system installed.

15°

10°

7. Consideration to the surface that the user will walk on with regards to following: i. Slope. ii. Capacity. iii. Surface texture (in relation to worker stability/traction).

8. If the system is required to traverse skylights a section of walkway conforming to AS1657 must be installed to provide safe access for the user over the skylight area(s).

9. The location of the system must provide safe entry and safe exit to the system for the user.

10. The design of the system as specified by the system manufacturer. 11. The installation and use of the system as specified by the system manufacturer. 12. The installation and use of the system as per AS/NZS1891.2 and AS/NZS1891.4. 13. The provision of system data plates as per AS/NZS1891.2 and AS/NZS1891.4.

Slope of Roof from horizontal

The slip resistant capacity of the surface will reduce the recommended angles

0° to 10° - Restraint Technique and Fall Arrest Cable and Rail Systems Acceptable

10° to 15° - Fall Arrest Cable and Rail Systems

Over 15° - Fall Arrest Rail Systems Only

0°

APPENDIX H – DESIGN & CONFIGURATION CONSIDERATIONS – VERTICAL LIFELINES AND RAILS

System Types and Description Vertical lifelines and vertical rails are substantially a vertical flexible cable or rigid rail that is attached to a structure or ladder. A Type 1 device as per AS/NZS1891.3 is attached to the flexible cable or rigid rail and connected directly to the user’s fall arrest harness via the frontal attachment point.

The user is permitted to ascend and descend the structure or ladder and in the event of a fall the activating lever or cam of the Type 1 device automatically locks onto the flexible cable or rigid rail. The types of systems are described as follows:

Proprietary Systems – Vertical Cable Vertical cable systems for which the fall arrest performance of any design can be determined by a method which has been verified by means of performance testing of prototypes over an adequately representative range of configurations.

They comprise flexible lines with end anchorages and dependent on the system length intermediate brackets (or cable guides allowing the removal of the cable), with a Type 1 device that is capable of passing across the intermediate brackets without disconnection from the line. The system components and recommended installation configurations need to be traceable to prototype or sample testing.

The systems are designed as a completed installation and must be installed by a competent installer as trained and accredited by the system manufacturer.

Proprietary Systems – Vertical Rail Vertical rail systems for which the fall arrest performance of any design can be determined by a method which has been verified by means of performance testing of prototypes over an adequately representative range of configurations.

They comprise a rigid rail generally manufactured from aluminium or other metallic structural member with mounting brackets and end stops, with a Type 1 device that runs along the rigid rail.

The system components and recommended installation configurations need to be traceable to prototype or sample testing.

The systems are designed as a completed installation and must be installed by a competent installer as trained and accredited by the system manufacturer.

System Design Requirements The following requirements shall be incorporated into the design of vertical lifelines and vertical rail systems including associated documentation where appropriate:

1. The system shall not allow the fall arrest loading exerted on a user’s harness to exceed 6kN when the user is equipped with and is correctly using personal fall arrest equipment as specified in AS/NZS 1891.4.

2. Methods or programs for the prediction or calculation of end anchorage or mounting bracket forces when arresting a fall shall be based directly on test results in respect of the number or users on the system.

3. For vertical lifelines the minimum wire cable diameter shall be 8mm and shall be made either from stainless steel or galvanised steel.

4. Swaged terminations shall be made from the same material as the cable or from a metallic material not known to cause an adverse reaction with the material of the wire cable e.g. dissimilar metal corrosion or cracking.

5. The number of users on the vertical flexible cable or rigid rail is determined by system manufacturer and the structure or ladder to which the system is attached.

6. For a single user on a vertical lifeline system, the components including terminations, cable and end anchorages are capable of supporting without failure a minimum static force of 15kN.

7. For multiple users on a vertical lifeline system, the components including terminations, cable and end anchorages are capable of supporting without failure the minimum static force as recommended by the system manufacturer, this force will be greater than 15kN.

8. For a single user on a vertical rail system, the components including terminations, cable and end anchorages are capable of supporting without failure a minimum static force of 15kN.

9. For multiple users on a vertical rail system, the components including terminations, cable and end anchorages are capable of supporting without failure the minimum static force as recommended by the system manufacturer, this force will be greater than 15kN.

10. If the Type 1 device is designed to be removed from the vertical lifeline or vertical rail system it shall be so designed that it can only be removed by at least two consecutive deliberate manual actions.

11. The Type 1 device shall be capable of supporting a force or 15kN in the direction of intended loading without breaking and without deforming in a manner which permits inadvertent detachment from the vertical lifeline or vertical rail system.

12. Vertical rail systems shall be fitted with end stops at the top and bottom of the system to prevent the Type 1 device from running off the rail.

13. Calculation of safe clearances shall be based on the information supplied by the system manufacturer and AS/NZS 1891.4.

14. The system must be installed as per the recommendations and documented installation instructions provided by the system manufacturer.

15. The system must be installed by a competent person as trained and accredited by the system manufacturer.

16. The use of components from multiple manufacturers in a system is not acceptable due to possible incompatibility and the likely event that they have not been tested together to demonstrate a known performance.

17. All system components shall meet or exceed the relevant requirements of AS/NZS1891.3.

18. Safe Work Australia Code of Practice – Managing the Risk of Falls at the Workplace states:

i. Ladder cages in fixed ladders do not stop a fall but simply funnel a fall and, in some cases, more injuries can occur from striking the protective back guards on the way down. The cages may also hinder rescues. Therefore, fixed ladders with angles exceeding 75 degrees to the horizontal should be fitted with a permanent or temporary fall-arrest system (anchorage lines or rails).

ii. The preferred angle for a rung ladder to be installed is between 70° and 75° from horizontal.

System Configuration

Vertical lifeline and vertical rail systems are:

1. Classified as a Limited Free Fall system as per AS/NZS1891.4 2. The Type 1 device is attached to the frontal attachment point of the user’s

harness and that the total assembly is a maximum length of 300mm. 3. The fall arrest equipment used shall limit the user’s free fall to less than

600mm. 4. Designed to be installed vertical or at an angle nominated by the

system manufacturer off true vertical or off true horizontal. i. AS1657 nominates the preferred angle for a rung ladder to be

installed is between 70° and 75° from horizontal. 5. Designed for single users unless approved by the system manufacturer

for multiple users. 6. Cannot be used for work positioning purposes.

Lifeline / Rail Positioning

There is occasionally a question over the correct position of a vertical rail or cable system – should it be in the centre of the ladder, or should it be located along the ladder stile, off to one side? There is no specific or correct answer to this question and each circumstance is unique. However the key considerations around positioning of the system are:

(1) Strength of the ladder – is it designed to accept limited free-fall or fall arrest loads?

(2) Construction material of the ladder – steel vs aluminium vs fibreglass. Each material has strength properties that need to be determined before a system can be fitted;

(3) Length of the distance between the traveller and the lifeline/rail – a maximum of 600mm free-fall is allowed for a system to be defined as limited fall (meaning the lanyard/shock absorber can have a 300mm maximum length).

(4) Width of the ladder – if the system is centrally located on the ladder, can a person wearing boots climb without impediment?

Contact the manufacturer or installer to determine the best solution before installation.

APPENDIX I – CORE COMPETENCIES FOR ALL ROLES IN AN ANCHOR OR LIFELINE SYSTEM INSTALLATION

A. Designers of anchor or lifeline systems The System Designer ensures the works are safe to install and are suitable for the intended end use (e.g. that the anchor or lifeline system will actually work for the needs of the users). Where possible the anchor or lifeline system should be designed for restraint technique use.

The System Designer shall ensure that - That the installation can be carried out in a safe manner so as not to place

the installers, users or public at risk - That the structure is assessed prior to the installation to

determine if engineering assistance is required - That suitable drawings, specifications and other documentation is produced

to ensure site personnel understand how the installation is to be carried out

- That suitable materials (anchors, lifeline components, fixings , paints, sealants etc.) are specified to ensure suitability for use, safety and durability

- An ability to assess the structure against design specifications and read drawings.

- To ensure that the installation is suitable for use, have an understanding of how to use a harness based system of work and concepts such as

• Ensuring there is always safe passage to, from and around anchor and lifeline installation. This may require the addition of AS 1657 solutions

• Ensuring that elements of the building such as glass façade elements are protected and ensure that operators and their equipment are not placed at risk by these elements

• Ensure that anchors and lifelines are not placed too close to fall potentials such as roof edges

• Ensuring there are no pendulum falls in harness based work, • Documenting how a person could be rescued from the system • Limiting the ability of a person to fall over an edge, • Where a potential of a fall over an edge seems inevitable, to make

some allowance for this thus preventing lanyard damage • How to deal with surrounding hazards such as Laserlite, skylights,

asbestos roofing, and plant in the way of anchors or lanyard runs etc.

• Limiting fall distances. • How to assess and deal with steep inclines such as steep roofs. • Understanding the tasks to be performed, and the purpose of the

system. Note for rope access works the designer may need to seek expert guidance to assist in this task

• Access to the system and access between levels. • Understand this Industry Code, relevant Australian Standards, work

instructions and manufacturer’s instructions • An understanding of the range of suitable products in the marketplace. • Demonstrate ability to understand how the products are installed and

be able to effectively transmit this information to site personnel.

B. Qualified Installer of anchor or lifeline systems As pointed out previously in this document the term “installation” can mean as little as drilling holes or as much as undertaking a wide range of engineering, testing and certification functions.

To be competent, Qualified Installers shall demonstrate the ability to: - Use the correct tools - Work in a safe manner so as not to place themselves or the public at risk

A practical working knowledge of Australian Standards, work instructions and manufacturer’s instructions

- Demonstrate ability to install equipment and document this - An ability to assess the structure against design specifications and read

drawings.

Minimum training requirements: o Safe working at heights, including rescue (AS/NZS 1891.4, appendix. E) o Construction induction training o Manufacturers training on installing specific product o Use of specific access equipment that may be required – e.g. Elevating

work platform

Installation experience: Installers should work under the supervision of an experienced operator who should be able to demonstrate a minimum level of experience in relevant works.

For rope access operatives, this experience can be demonstrated through the use of a log book as it is required to keep records of hours being spent. Non-rope access staff may be able to utilise alternative means to demonstrate/record hours being spent installing systems.

The Workplace Manager should ensure that senior installation personnel have a recommended relevant competency of at least 50 hours general installation works, with 10 hours directly related to each product that is to be installed. There should be regular assessment of the person’s competency by instruction and observation. This experience must include working in similar environments with the specific product.

As the senior installer will generally be supervising other personnel, it must be ensured that the skills held are suitable to do this.

Demonstrate experience in ability to do the work by way of demonstrating hours on the work under someone else’s supervision by way of a log book, or some other way.

The work experience recorded shall be related to the task, and related activities.

The installer shall be trained and accredited by the manufacturer of the anchor or lifeline in the specific product installation with training updated every 24 months to take into account changes in Australian standards and product development. Training shall

be specific to that product and the manufacturer shall certify the installer, designer and certifier as competent to perform those tasks.

To ensure that the designer has suitable experience, the following minimum qualifications are expected to be held by this person:

• Safe working at heights or equivalent rope access course (AS/NZS 1891.4, Appendix E, ARAA, IRATA), the choice of which should be relevant to the system design/function;

• Manufacturers training on product, fixing, structure and design layout.

Design experience: Demonstrate an ability to design a system that protects a person whilst they are connected to the system carrying out particular tasks.

Demonstrate an ability to carry out the design work by way of demonstrating hours under supervision by way of a log book, or some other way such as demonstration of experience in the area by way of previous successful projects.

The work experience recorded shall be related to the task, and related activities. In the case of a rope access installation, due to additional complexity, demonstrate specific experience in this area.

Demonstration of suitable experience is suggested as follows: *Designing at least 5 complex systems. There should be regular assessment of the persons competency by instruction and observation by the Workplace Manager.

C. Initial certifier of anchor or lifeline systems This person has the responsibility to review and inspect the final installed system and documentation and to provide a certificate of conformance to this Industry Code for the entire system, which includes documentation.

This person shall demonstrate competency as follows: - A practical working knowledge of the relevant Codes of Practice & Standards - An ability to assess the structure against design specifications and read

drawings. - Common installation errors - That the anchor and lifeline is installed to the designer requirements,

structural requirements, and the manufacturer’s installation instructions. - The ability to overview testing (where necessary) and verify pass / fail criteria - An understanding of suitable layouts and task appropriate for the

works required.

The certifier should possess the following minimum training/qualifications. • Safe working at heights or equivalent rope access course (AS/NZS

1891.4 Appendix E, ARAA, IRATA), the choice of which should be relevant to the system design/function;

● Manufacturer’s training and accreditation on product, fixing, structure and design layout.

Certifier’s experience: The certifier should demonstrate at least 2 years relevant industry experience (e.g. . Designing, installing or using anchor based systems systems)

D. Engineer Eligible for membership of Engineers Australia and has experience to assess the structure of the building (See definition)

- A practical working knowledge of the relevant codes of practice and standards - A demonstrated history in systems and anchor design and layout

E. Inspector of anchor or lifeline systems (Referred to as a “Re-certifier”)

Shall demonstrate competency as follows: - A practical working knowledge of the relevant and codes of practice

and standards - An ability to identify defects and deterioration in anchor installations

and to record the findings. - Ability to assess changes to the structure that affect the system being

used as intended. - Ability to use an anchor or lifeline based system. - Ability to review the system documentation. - Ability to make judgement assessments where existing anchor or lifeline

system may not have all expected documentation and labelling information available.

- Be a manufacturer accredited/certified inspector for each particular system that they are recertifying.

It is expected that the re-certifier will hold the following minimum training/qualifications:

• Safe working at heights or equivalent rope access course (AS/NZS 1891.4 Appendix E, ARAA, IRATA), the choice of which should be relevant to the system design/function;

• Manufacturer’s training on product, fixing, structure and design layout.

Re-Certifier’s experience: The re-certifier should demonstrate at least 1 year relevant industry experience (e.g. a combination of designing, installing, inspecting or using anchor based systems systems).

APPENDIX J - CERTIFICATION / COMMISSIONING REQUIREMENTS

PRO-FORMA EXAMPLE – PERMANENT ANCHOR INSTALLATION COMPLIANCE STATEMENT

To be completed by the initial certifier,

Contact details of company Address Email Phone Fax

1. System commissioning date

2. Required frequency of inspection

(Specify date - Every x months)

3. Testing, inspection requirements:

(Specify testing e.g. Load test or visual)

4. Location of the system (For a complex system attach sketch of layout)

5. Product description and serial numbers

(Insert serial numbers)

I certify that the details set out on this document are true and that the system has been laid out, designed, installed, certified and documented in accordance with the requirements of the Industry Code.

Signed……………………………

Print name………………………………………Phone……………………………Date……………………

INTENDED SYSTEM USE

Provide brief statement of intended system use TASK

1. E.g. Gutter cleaning 2. 3. 4.

NAME & CONTACT DETAILS OF ALL COMPANIES RESPONSIBLE FOR INSTALLATION:

* Note that the design phase may involve several different parties

By signing this document, the certifier confirms that all anchors have been labelled as below:

All permanent anchor points are marked with the following information. This should, where practical, be fixed to or at, each anchor but may, in some cases be fitted at one location such as the access door to a roof. All anchors should be marked with at least a serial No or batch No to enable traceability of individual anchors.

Subject to the above comments, marking should include:

● Manufacturer’s/installer’s contact ● Load rating and direction. ● Specific use if not also suited as a fall protection anchor (min. 15 kN

ultimate ) ● Most recent inspection/service date

Attach sketch / plan of anchor layout and system manual.

DESIGNER* ● Layout ● Structural ● Product ● Rescue

STRUCTURAL ENGINEER (Where applicable)

● Company and Name

MANUFACTURER ● Product Specification ● Installation instructions ● Certification of installer

INSTALLER ● Installation

● Testing

APPENDIX K - VERIFICATION TESTS FOR ANCHORS

SITE VERIFICATION DIRECTION OF PULL

The tests shall be carried out in tension, though on occasions they may be carried out in shear – where this is the case it should be specified by the designer or Structural Engineer.

TEST LOADS Apply 50% of the design load for a minimum of 3 minutes (e.g. . for a 15kN anchor, apply 7.5kN).

The method will vary depending upon what style of anchor is being used, as follows:

Appendix C anchor

type

ANCHOR TYPE COMMISSIONING TESTS OR INSPECTION

B Anchor welded to structural steelwork

1) Demonstrate welding to AS 1665 Category 2.

2) Load test to 50% in tension. 3) Non-destructive

examination to AS1665 once installed.

A Anchor cast into concrete 1) Proof load tested to 50% of rated capacity for 3 minutes once design strength of concrete is achieved.

2) Type test of anchor product

B Anchor bolted to steelwork – structural

1) Visual inspection.

C Anchor bolted or riveted to steelwork – lightweight (purlins etc.)

1) Visual inspection.

A Anchor through-bolted to concrete

1) Visual inspection

A Anchor through bolted to masonry (excluding concrete)*

1) Proof load to engineers requirements.

A Anchor drilled into concrete 1) Proof load to 50% of rating

A Anchor drilled into masonry 1) Proof load to engineers specification

G Anchor, girder mount - this may be a clamp on girder mount or a girder trolley

1) Visual inspection

E, F, G, H

Anchor, portable incl. davit, tripod, cross beam, bridge and counterweighted

1) Visual inspection or to manufacturer’s requirements.

2) If the action of the device relies on a permanent part of the structure (i.e. Davit bases in floor of structure) load test to 50% in tension or to designer’s specification.

C Anchor, through roof mount, not relying on dynamic action of roof

1) Visual inspection

D Anchor top fixed to roof sheet – these are ALL assumed to rely on dynamic or load spreading capabilities of roof to operate correctly

1) Visual inspection

APPENDIX L – INSPECTION CHECKLIST – GENERAL INSPECTION CRITERIA

The inspection checklist below is a list of general considerations of an inspection process. This is a guide only and checklists should be based on the manufacturer’s requirements, nature of the anchors involved, their location and any specific environmental conditions that may impact the performance of an anchor or system.

Refer to additional specific instructions for inspecting: ● Welded anchors ● Bolted anchors ● Cast in anchors ● Surface mount anchors ● Friction anchors ● Glued-in anchors ● Horizontal systems ● Vertical systems

PROJECT AREA ITEM TICK OR CROSS

Design ● Determine if the system layout is still suitable for the tasks for which it is being used / was originally designed

Installation ● Visually inspect for: ● Corrosion ● Data plate is in-tact ● Number of users noted on data plate ● System rating noted on data plate ● Any evidence of light degradation ● Any evidence of impact on an anchor or system

Testing (if required)

● Complete static (proof load) testing if required

System configuration

● Visually inspect for: ● All system components, including PPE

equipment are in-tact and still safe for use (harnesses, lifeline travellers, shock absorbers, ropes, access ladders, ladder brackets)

Operations Manual

● Is in place and accessible by users. All components of the original manual are in-tact, including manufacturer’s instructions, use requirements and inspection checklists from previous inspections

APPENDIX M – ANCHOR LAYOUT AND SPACING GUIDELINES

The following images are typical examples of anchorage layout principles. The list is not exhaustive – it is intended to provide general guidelines around product placement such that safety can be maintained. All layout scenario drawings are in ‘plan’ view.

Each scenario is explained using a simple guideline. A tick reflects a suitable design, a cross reflects a scenario where there is a risk of a fall occurring, a design flaw or other issue and is therefore not recommended.

Legend

Scenario A: A centrally located single anchor point on a square shaped building, with a fixed length lanyard that extends no further than the shortest distance.

Tick : This system gets a tick because a person cannot access the corners and is prevented from falling.

Scenario B: A centrally located single anchor point on a square shaped building, with a fixed length lanyard that extends to the corner.

Cross : This system allows a fall. The rope or tethering device can be extended to

the corners. If a person accesses the corner, there is a possibility they could fall

over the building edge and be subjected to a pendulum fall.

A Pendulum Fall

The risk of a pendulum fall is not limited to the high fall distances – the potential for severing of the safety line is greatly increased, as well as the potential for

Scenario C: A centrally located single anchor point, with 4 separate anchors located

Tick : This system gets a tick as

the corner diversion anchors provide a an additional

connection (or diversion) point, such that if a person was to fall, their risk of a

Scenario D: Task – gutter maintenance. One part of the roof of a rectangular building is shown, where a gutter is located on one side. Access from the roof shall be via a set/secure location to set a ladder bracket. The location of a suitable anchorage point in the corner is also available for attachment to allow the worker to transition from the temporary ladder onto the roof surface from the outside of the building.

Tick : This system gets a tick as the corner diversion anchors provide a safe point to connect to during access. They can also act as an interim connection point during transition to the centrally mounted anchors, such that if a person was to fall, their risk of a pendulum fall has been eliminated. The gutter can

now be cleaned using the centrally mounted anchorage points for the task, with the corner anchors re-used again during egress from the building.

Scenario E: Task – gutter maintenance. One part of the roof of a rectangular building is shown, where a gutter is located on one side. Access from the roof has been set centrally using a ladder bracket. There are two centrally located anchors designed to be used to cleaning the gutters

Cross : This system gets a cross as there are significant risks to the users of the system.

Issue 1: Insufficient anchors have been provided to ensure the safety of the operators. Initially, if a user accesses the roof via a temporary ladder, during the transition to the roof surface, they are not protected from a fall by having access to a secure connection point.

Issue 2: The anchors are too far apart to be able to connect with a standard lanyard. Even though a user may reach the centre of the roof by walking and connecting, they are unconnected. Additionally, there may be brittle roofs, skylights, uneven surfaces and other hazards present where a fall is possible.

Issue 3: With a longer lanyard or rope line, the user is exposed to an excessive pendulum fall if they access the corners of the roof.

Scenario F: Spacing distances between anchors. This diagram shows a rectangular roof and denotes important information about the spacing distances between anchors.

Anchor installation in ‘Shear’ This means that the anchor must always be installed in a way that the force that would be applied in the event of a fall would be perpendicular to the direct of installation.

Direction of Load

Key criteria to be applied during all anchor layout designs: (1) Distances marked as X are all to be equal (2) X is not to exceed 6m (main anchor) (3) Y is not to exceed 2m (diversion anchor) (4) All anchors to be rated to a minimum 15kN

Essential: (1) Always install in shear (2) Angle of pull not to exceed 20%

Anchor installation in ‘Tension’ This means that the anchor could be installed in a way that the force that would be applied in the event of a fall would be in direct line with a fall force that may be applied. This is very dangerous.

Direction of Load

Scenario G: An example of a typical anchor installation design that has considered of all scenarios, risks and hazards identified above.

Do NOT install in tension

APPENDIX N – HORIZONTAL SYSTEM LAYOUT AND SPACING GUIDELINES

The following images are typical examples of HLL layout principles. The list is not exhaustive – it is intended to provide general guidelines around product placement such that safety can be maintained. All layout scenario drawings are in ‘plan’ view.

2.3

Tick : This system gets a tick as the system is set back 2.3m from the edge of the roof, ensuring the use of a 2.0m lanyard and fully body harness means

the person cannot fall over the leading edge. Access to the system is proposed from the gutter side, with a ladder bracket to secure the ladder

to, and an anchor point located to ensure the user can connect to the system before transitioning onto the roof and connecting to the horizontal

lifeline.

Set back 2.3m

Tick : This system also gets a tick as the system is set back 2.3m from the edge of the roof, ensuring the use of a 2.0m lanyard and fully body harness

means the person cannot fall over the leading edge. Even when carrying equipment and accessing the gutters for cleaning, under full restraint, the

line prevents a person from reaching the edge. Additionally, access to the roof is from within the roof structure, further reducing the risk of a fall during system entry. Note that the anchors set at the ends of the system are also

2.3m back from the edge.

APPENDIX O – COMMON ISSUES RELATING TO POOR SYSTEM DESIGN

ISSUE DISCUSSION

Incorrect equipment ● Harness based system may not be the most suitable solution for the works – consider higher order controls such as fixed guard-railing, walkways, scaffold, work platforms as alternatives.

● System does not allow users to undertake works required. E.g. can’t reach gutters, rope access layout leaves voids on façade that cannot be safely reached

● Rescue unable to be effected safely or in timely fashion

● Injured person cannot be raised or lowered (for example) to a place of safety

● Lanyard and line runs are impeded by plant or other building features

● Inadequate safe access to and from anchor system and between anchors

Inadequate detail ● Edge detail of façade has not been considered in relation to lanyard/lifeline/SRL cable damage

● Operators cannot easily climb over and around building features

● Potential damage to building features and to operator’s equipment (e.g. Running ropes over glass façade – broken glass leading to extreme danger to user, public and user’s equipment)

● Drill in anchors used in tension – this is not accepted by AS/NZS 1891, AS/NZS 4488 and AS/NZS 5532

Poor specification ● Immediate choice of an anchor based system on cost rather than the tasks to be completed, which might be better served utilising a lifeline system

● Use of drill-in anchors commits client to long term costs in additional testing

● Use of materials that are not adequately corrosion resistant or suitable for task

● Use of deforming anchors in situations where they may be loaded in service – e.g. Rope access

APPENDIX P - SUGGESTED CHECKLIST FOR A SYSTEM CERTIFIER

PROJECT AREA

ITEM TICK OR CROSS

Design ● System layout suitable for works to be carried out? ● Structural considerations (e.g. Has suitable

engineering overview been applied?) ● Selection of suitable products (this covers anchor,

fixings, sealants, corrosion resistance etc.) ● Has a viable rescue method been allowed for? ● Is there safe access to and from anchor system and

around works? ● Are any building features over which ropes may

need to pass suitable for loads or have protection allowed for (i.e. Sharp edges, glass balustrades etc.)?

Installation ● Are works completed in a workmanlike manner? ● Have fixings and anchors been installed as per

manufacturer’s specifications? ● Have works been properly cleaned up? ● Does the installation works follow the

specifications and drawings?

Testing / Commissioning / Certification

● Has all required testing been successfully undertaken?

● Has all necessary remedial works resulting from testing been adequately completed?

● Has all required labelling and signage been provided?

● Are all serial numbers and batch numbers recorded?

● Has a suitable system manual been produced?

Documentation and handover to Workplace Manager

● Has system manual been handed to Workplace Manager?

● Has documentation adequately set out maintenance and inspection requirements and listed necessary operator skills, supervision levels and any special PPE and protection methods required?

● Has a formal handover with Workplace Manager been carried out?

● Has the issue of operator training been adequately covered?

APPENDIX Q - SUGGESTED CHECKLIST FOR A WORKPLACE MANAGER

PROJECT AREA

ITEM TICK OR CROSS

Design ● A complete design and layout of the proposed system is provided in ‘plan’ view

Installer Qualifications

● The installer can provide: ● Verification of Insurance coverage for Public

Liability, Professional indemnity and Workers Compensation insurance coverage

● Evidence of manufacturer training/certification as an installer

● Evidence of working at heights training

Installation Preparation

● Engineered drawings or opinions of the system layout are suitable (if required);

● Results of a calculation program verifying the loads of the system will not affect the structure of the building;

● Evidence that the product selection being offered by the installer is suitable for the location/materials to which the installation is being made.

Testing / Commissioning / Certification

● A copy of the operations manual for the system including use instructions, numbers of users, tasks for which the system can be used, inspection requirements, Installation certificates, Proof load test results and/or certificates, manufacturer endorsements

Documentation to be kept in suitable storage location for ongoing access

● Folder with all required documentation is provided for access by the facility manager and users if required

● Evidence of Hand-Over and Training provided to ensure safe use of the system

APPENDIX R - SUGGESTED CHECKLIST FOR ANCHOR SYSTEM INSPECTION – ONGOING RE-CERTIFICATION

SECTION DETAIL Pass or fail

DOCUMENTATION ● Is there a system manual? ● Is the system manual adequately detailed? ● Does the system manual set out a

proposed rescue method? ● Does the system manual set out inspection

and test methods? ● Does the system manual provide a layout of

the anchor system? ● Does the system manual provide serial

and batch numbers of all anchors? ● Does the system manual adequately show

the method of use/rigging from the anchors?

● Does the system manual detail the works intended to be carried out from the anchor system?

● Does the system manual detail any constraints on use of anchors i.e. Capacity <15Kn?

● Does the system manual contain the original certifier’s sign off confirming the system complies with WAHA Industry Code?

● Does the system manual demonstrate how to deal with building features where additional protection may be required (e.g. Glass balustrades, sharp edges etc.)?

● Does the system manual detail any special components of PPE, slings etc. that may be required for specific use of the system?

LAYOUT ● Is the layout of the anchor system suitable for safe use for the intended works (i.e. The works specified in the system manual)?

● Is system layout suitable to avoid “voids” at corners ?

LABELLING ● Is system adequately labelled? ● Have updated labels been fitted at THIS

inspection to demonstrate anchors are safe for use?

CORROSION / SUBSTRATE

● Have all anchors and substrate to which they are fitted been inspected for:

➢ Corrosion

Where there is inadequate information available to satisfactorily tick above boxes, then all or some of the works may require investigation to update the works. Note that this may place the Re-certifier in a position of becoming the System Designer of the system and as such, great care must be taken with re-certifying or updating existing installations.

While remedial or update works are being undertaken, the system should be tagged out of service.

➢ Degradation of substrate ➢ Degraded sealant

● Where documentation requires it, have anchors been removed to inspect internally for corrosion?

FIXINGS ● Have all fixings been inspected for: ➢ Corrosion ➢ Loose fixings ➢ Degraded adhesives ➢ Degraded sealant ➢ Installation to manufacturer’s

requirements

ANCHOR CONDITION ● Have all anchors been inspected for: ➢ Serial / batch numbers ➢ Corrosion ➢ Loose components ➢ Distorted components ➢ Current inspection tags (if system

was not “in date”, this may raise questions about its overall management)

● Are any devices used in protection of equipment or building features (e.g. glass balustrades) present and in useable condition?

TESTING ● Has testing as required by the system manual been carried out?

● Was all testing successful (i.e. All items passed)?

● Has any issues raised by the testing been remedied safely?

GENERAL ● Are any components of PPE or items such as slings which may have been supplied for use with the system present, within date and in serviceable condition?

● Is the system suitable to be re-certified and continue to be used?

APPENDIX S - FREQUENTLY ASKED QUESTIONS AND ANSWERS The following is predicated upon claiming compliance with this Industry Code:

Q: Can I install an anchor or lifeline system without using a structural engineer? A: Yes, if the anchors are installed to the substrate prescribed by the manufacturer and following the installation requirements as documented.

Q: If I have a n anchor complying with AS/NZS 1891.4, do I have to replace it? A: A risk assessment should be made as to whether the anchor(s) are safe to use or not. If it’s not safe to use, it should be removed, irrespective of claims of compliance at a point in time.

Q: If the system installer cannot demonstrate they comply with the requirements of this Industry Code, can the system they install be safe and compliant? A: No. If compliance with this Industry Code is claimed then the system must be designed and installed, then certified, strictly under the requirements of this document.

Q: If anchors (new or existing) are drilled in (e.g. Friction or glued in), can they be used in axial tension (direct pull out)? A: No. Anchors used in axial tension are more likely to fail and pull out.

Q: If an existing system does not or is found not to comply, can it be upgraded to compliance status? A: Yes it can. However it may require extensive engineering and upgrading works. In the end, it needs to comply as if it were a new project for it to be safe to use. Whilst making a determination, tag the system out so it can’t be used and follow the requirements of this code.

Q: If a system provides no safe manner to reach the anchor points or anchor system, can it still claim compliance with this Industry Code? A: No. A critical part of “compliance” with this Industry Code is the issue of safe access to, from and around the anchor system.

Q: If a certificate of compliance has not been issued on a new project, can compliance still be claimed and can the system be used? A: No.

Q: If a fall protection design/installation company provides a lifeline, anchor or rope access anchor system, does this system comply with this Industry Code? A: If the requirements of this code have been met, then it does comply and is safe for use.

Q: If the documentation for a system does not adequately address the issue of rescue, can the system still claim compliance? A: No. Again, a suggested rescue method, including addressing the suitability of anchors being used in the rescue that may have been damaged in a fall, must be addressed as a critical component of the anchor system.